Use Epoxy Joint Sealer to Stop Concrete Floor Vibration and
Damage
Many heavy industrial settings, including paper warehouses,
steel and other heavy-weight or high-traffic applications suffer
from shaking concrete floors. The source of the vibration is
most often caused by rolling equipment crossing expansion joints
cut in the concrete when poured. Cement contractors place these
expansion joints in the floor in order to allow for the
shrinkage that occurs in the concrete slabs as they cure. The
joints are also helpful if the slab experiences major
temperature changes.
Bridges, highways, and sidewalks may expand and contract
considerably. Most modern buildings, however, are climate
controlled with temperature variations within a 10-15 degree
range. As a result, these expansion joints are more of a problem
than a solution.
Flexible caulks have been used in expansion joints to help
transition between the slabs yet allow for some movement.
Unfortunately, that movement can become a problem and cost if
frequent or extensive.
A better solution is to epoxy the slabs together with 100% solid
epoxy and color quartz. The epoxy-quartz filler levels the rut
between slabs, thus eliminating the vibration, wear, and
structural damage that would otherwise be caused by moving
equipment. The quartz-epoxy mix withstands test strengths of
22,000 psi.
A recommended first step in the application process is to set a
masonry blade on a skilsaw at 1/4 to 1/2 inch and run it down
the expansion joints, cleaning both sides. Flexible chalk will
melt out of the joints during this operation. Once the joints
are cleaned, color quartz is swept into the joints until
slightly lower than flush with the floor surface. Clear or
colored 100% epoxy is then poured over these joints until
saturating the quartz and rising level with the floor. 12 hours
later the joint will need to be re-inspected and topped off.
Often these joints have openings at the bottom and some epoxy
may leak through. The wetted color quartz will remain and block
leak-through on the second application. It is important to come
back to the floor between 10 and 12 hours later to scrape off
excess epoxy. Too long a wait and the epoxy becomes hard to
shave; too little setup time and the epoxy may be tacky or
sticky. Using a 4-inch razor scraper with a long handle allows
each side of the joint to help guide the scraper and provide a
smooth, even filling over the joint between the slabs. If done
well, the rolling equipment may never notice joints again and
the floor life will be extended with reduced need for
maintenance and repair.
The cost of filling deep holes and badly eroded floors can be
reduced by using color quartz and a filler and wear inhibitor.
Mixing 100% epoxy with color quartz to 28 lb. per gallon gives a
trowel mix with a peanut butter consistency. This mix can be
placed in holes using a trowel or putty knife. Small vertical
surfaces are best filled by using a heavy rubber glove and
applying the mixture by hand with a rubbing motion.
One floor coating manufacturer that has taken the lead in joint
repair is Durall Industrial Flooring of Minneapolis, MN. Durall
is the only industrial flooring manufacturer that also makes
over 500 specialty cleaners, allowing them to produce special
preparations of cleaners and application systems designed to
assure optimum flooring adhesion and wear results.
Photo examples of the joint sealing process are available at
www.concrete-floor-coatings.com/photos/jointsealer
For more information, contact Harvey Chichester at
harvey@concrete-floor-coatings.com
Phone: 1-800-466-8910 or 952-888-1488 (24/7)
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